Flame-resistant heat treatment furnace

ABSTRACT

A furnace to flame-resistantly treat a precursor fiber strand by sending hot air to a heat treatment chamber through a hot air blowing nozzle in a direction parallel to a running direction of the strand is provided. The hot air passes through a porous plate and a rectifying member satisfying the following conditions: (1) A/B≧4.0; (2) 0.15≦α≦0.35; (3) 0≦B−d≦20; and (4) 80% or more of the area of one opening of the porous plate when facing surfaces of the porous plate and the rectifying member overlap is included in one opening of the rectifying member, where A is the rectifying member hot air passage distance (mm), B is a horizontal maximum distance (mm) of one opening of the rectifying member, α is a rate of hole area of the porous plate, and d is the porous plate equivalent diameter (mm).

CROSS REFERENCE TO RELATED APPLICATION

This application is a 371 of PCT/JP2012/068914, filed on Jul. 26, 2012,and claims priority to Japanese Application No. 2011-165816, filed onJul. 28, 2011.

TECHNICAL FIELD

The present invention relates to a flame-resistant heat treatmentfurnace that is appropriately used to manufacture a carbon fiber.

BACKGROUND ART

As a method of manufacturing a carbon fiber, a method is widely known inwhich a precursor fiber of a carbon fiber is subjected to aflame-resistant treatment and a carbonizing treatment.

As the flame-resistant treatment used to manufacture the carbon fiber,for example, a method is widely employed in which a heat treatment isperformed on the precursor fiber inside a heat treatment chamber in anoxidization atmosphere by hot air.

Incidentally, since the flame-resistant treatment is a treatment thataccompanies an exothermal reaction, it is important to suppress avariation in reaction by keeping the uniform heat transfer performancethroughout the inside of the heat treatment chamber.

Therefore, according to JP 10-237723 A (Patent Document 1), a heattreatment chamber through which a precursor yarn passes is provided witha blowing port that blows hot air in a direction following a precursoryarn passage path, and a cross-sectional area Ss of the heat treatmentchamber and a cross-sectional area Sf of the blowing port in a directionperpendicular to the precursor yarn passage path have a relation ofSs/Sf≦2, so that a satisfactory parallel stream is formed along the yarnpassage path. Further, according to JP 2002-194627 A (Patent Document2), there is disclosed a nozzle in which a hot air introduction regionis formed by a guide vane, a porous plate, and a rectifying plate,dimensions of respective portions inside a heat treatment furnace aredefined by a predetermined relation, and a uniform blowing wind speeddistribution is set so that hot air blows in parallel to a yarn.

Furthermore, according to a flame-resistant furnace disclosed in JP2008-144293 A (Patent Document 3), the flame-resistant furnace includesa gas introduction portion that causes an oxidizing atmosphere gas toblow in a direction substantially perpendicular to a running directionof a polyacrylonitrile-based fiber bundle and a gas discharge portionthat is installed to face the gas introduction portion and dischargesthe oxidizing atmosphere gas, and the gas introduction portion isprovided with a porous plate having an opening with a circle of adiameter of 10 mm in consideration of a blockage of a hot air nozzle.

CITATION LIST Patent Document

Patent Document 1: JP 10-237723 A

Patent Document 2: JP 2002-194627 A

Patent Document 3: JP 2008-144293 A

DISCLOSURE OF THE INVENTION Problem to be Solved by the Invention

However, in the flame-resistant furnace disclosed in Patent Document 1,it is mentioned that a variation in the wind speed of the hot airblowing from the blowing port of the nozzle needs to be within ±10%.However, only the components thereof are illustrated, and the detaileddimensions of the components and the relation of the components are notmentioned.

Further, in the flame-resistant furnace disclosed in Patent Document 2,the rectifying region is formed as multiple stages in order to reduce avariation in wind speed. For this reason, the pressure loss increases,and the length of the nozzle in the yarn direction increases.Accordingly, since there is an increase in the size of the region wherethe hot air does not flow in the flame-resistant furnace, it is notpossible to remove the heat of the precursor fiber that keeps theexothermal reaction. Thus, the risk of a runaway reaction increases.

Even in the carbon fiber manufacturing process, since theflame-resistant treatment causes the oxidation reaction that generatesthe heat of the precursor fiber bundle, single fibers may be easilyfused due to the hot air inside the flame-resistant furnace or the heatgenerated by the oxidation reaction. The flame-resistant fiber bundlehaving the fused single fibers noticeably degrades the quality of thecarbon fiber. For example, in the subsequent carbonizing treatment, theyarn is easily fluffy or cut and various characteristics of the yarn maybe easily degraded.

In order to prevent the fusion of the flame-resistant fiber bundle, forexample, a method of applying oil to the precursor fiber bundle isknown, and various kinds of oil have been examined using theabove-described method. Among these, silicon oil is frequently used inthat the oil has high thermal resistance and effectively suppresses thefusion. However, the silicone oil applied to the precursor fiber bundleis partially volatilized by the high heat of the flame-resistanttreatment, and easily stays in the hot air.

When the dust stays inside the flame-resistant furnace, the wind speedrectifying porous plate installed in the blowing surface of the hot airblowing port is blocked, so that the hot air may not be circulated. Whenthe hot air may not be circulated inside the heat treatment chamber, theheat of the precursor fiber bundle may not be sufficiently removed, andthe yarn of the precursor fiber bundle is cut. The precursor fiberbundle of which the yarn is cut is further tangled with the otherprecursor fiber bundles, so that the yarns of the precursor fiberbundles running in the other running regions are cut. As a result, afire takes place in the worst case, and hence the cut yarns disturb thestable operation of the flame-resistant furnace.

In view of such circumstances, a rectifying technique is disclosed whichuses the porous plate having the opening with the circle of 10 mm as thecomponent of the hot air nozzle disclosed in Patent Document 3. However,in the flame-resistant furnace that supplies the hot air to theprecursor fiber strand in the perpendicular direction at the blowingwind speed of 0.3 m/s to 1.5 m/s, when the wind speed is uniformlycontrolled and the air blowing amount increases, the precursor fiberstrand is easily cut, so that the adjacent fibers are frequentlytangled.

An object of the invention is to provide a parallel stream typeflame-resistant furnace that is appropriately used to manufacture carbonfiber having large total fiber fineness, obtains high productivity fromhigh heat transfer performance with an increase in treatment speed, andperforms a heat-resistant treatment on a running precursor fiber bysupplying hot air in a direction parallel to the running direction,where a structure of a hot air nozzle becomes simple and a hot airblowing speed distribution becomes uniform while using a componenthaving a large opening so as to prevent a blockage of a nozzleparticularly caused by a silicone compound, so that the heat transferperformance may become uniform throughout the inside of the heattreatment chamber.

Means for Solving Problem

The invention includes the following aspects.

[1] A flame-resistant heat treatment furnace including:

a heat treatment chamber that causes hot air to flow in a directionparallel to a running direction of a precursor fiber strand and heatsthe precursor fiber strand;

a hot air blowing nozzle that introduces the hot air into the heattreatment chamber; and

a hot air suctioning nozzle that is installed at a position away fromthe hot air blowing nozzle and suctions the hot air,

wherein the hot air blowing nozzle includes a porous plate and arectifying member that satisfy the following conditions (1) to (4), andthe hot air is sent to the heat treatment chamber through the porousplate and the rectifying member, and

wherein the conditions are set as follows:

(1) A/B≧4.0;

(2) 0.15≦α≦0.35;

(3) 0≦B−d≦20; and

(4) 80% or more of an area of one opening of the porous plate whencausing facing surfaces of the porous plate and the rectifying member tooverlap each other is included in one opening of the rectifying member,A indicating a hot air passage distance (mm) of the rectifying member, Bindicating a horizontal maximum distance (mm) of one opening of therectifying member, α indicating a rate of hole area of the porous plate,and d indicating an equivalent diameter (mm) of the porous plate.

[2] In the above-described flame-resistant heat treatment furnace, theequivalent diameter d (mm) of the porous plate may satisfy a condition(5) of 10≦d≦20.

[3] In the above-described flame-resistant heat treatment furnace, anopening pitch P1 (mm) of openings of the porous plate and an openingpitch P2 (mm) of openings of the rectifying member may satisfy acondition (6) of 0.995×P2≦P1≦1.005×P2.

[4] In the above-described flame-resistant heat treatment furnace, adistance y (mm) between the facing opening surfaces of the porous plateand the rectifying member may satisfy a condition (7) of 0≦y≦7.

[5] In the above-described flame-resistant heat treatment furnace, across-sectional shape of the rectifying member in the hot air passagedirection may be a lattice shape or a honeycomb shape.

[6] In the above-described flame-resistant heat treatment furnace, theporous plate and the rectifying member may be connected to each other bya positioning member at a connection portion.

[7] In the above-described flame-resistant heat treatment furnace, theporous plate and the rectifying member may be detachable from eachother.

[8] In the above-described flame-resistant heat treatment furnace, thehot air blowing nozzle may include a direction changing plate thatchanges a hot air flow direction, and may satisfy a condition (8) of(x/L)<0.030 and a condition (9) of (w/L)<0.50, x indicating a distance(mm) between the porous plate at a nozzle tip and the direction changingplate at the nozzle tip, L indicating an entire length (mm) of the hotair blowing nozzle in the depth direction, and w indicating an inletwidth (mm) of the hot air blowing nozzle.

[9] In the above-described flame-resistant heat treatment furnace, aninstallation position of the porous plate may be adjustable.

[10] A method of manufacturing a carbon fiber including: heating acarbon fiber precursor strand by using the flame-resistant heattreatment furnace.

Effect of the Invention

According to the invention, since the hot air blowing speed distributionbecomes uniform by the simple hot air blowing nozzle structure duringthe flame-resistant treatment, the heat transfer performance may becomeuniform throughout the inside of the heat treatment chamber. Further,since the porous plate having a large opening is used, the blockage ofthe nozzle caused by a silicone compound may be easily prevented.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a side cross-sectional view schematically illustrating astructure of a representative flame-resistant heat treatment furnaceaccording to this embodiment.

FIG. 2 is a top cross-sectional view schematically illustrating theinside of the flame-resistant heat treatment furnace.

FIG. 3 is an enlarged top view schematically illustrating a structure ofa hot air blowing nozzle.

FIG. 4 is a front view schematically illustrating a displacement ofopenings of a porous plate and a rectifying member of the hot airblowing nozzle when viewed from the rectifying member.

FIG. 5 is a front view schematically illustrating a state where openingcenters of the porous plate and the rectifying member of the hot airblowing nozzle match one another when viewed from the rectifying member.

FIG. 6 is a front view schematically illustrating a state where openingpositions of the porous plate and the rectifying member of the hot airblowing nozzle of the flame-resistant heat treatment furnace of theinvention are displaced from one another when viewed from the porousplate.

FIG. 7 is a front view schematically illustrating a method of openingthe porous plate of the hot air blowing nozzle of the flame-resistantheat treatment furnace of the invention.

BEST MODE(S) FOR CARRYING OUT THE INVENTION

Hereinafter, an exemplary embodiment of the invention will be describedwith reference to the drawings.

FIG. 1 schematically illustrates a longitudinal sectional view of aflame-resistant heat treatment furnace of this embodiment. Aflame-resistant heat treatment furnace 1 of this embodiment includes aheat treatment chamber 2 that is disposed inside the flame-resistantheat treatment furnace 1, first guide ports 9 a that are formed in aslit shape and are used to introduce a precursor fiber strand 10 runningin a sheet shape into the heat treatment chamber 2 or draw the precursorfiber strand to the outside of the heat treatment chamber 2, secondguide ports 9 b that are formed in a slit shape and are used to draw theprecursor fiber strand 10 running in a sheet shape to the outside of theheat treatment chamber 2 or introduce the precursor fiber strand intothe heat treatment chamber 2, hot air blowing nozzles 4 that aredisposed at the interior side of the first guide port 9 a of theprecursor fiber strand 10, hot air suctioning nozzles 5 that aredisposed at the interior side of the second guide ports 9 b of theprecursor fiber strand 10, guide rolls 3 that are installed at the upperand lower stages of the first and second guide ports 9 a and 9 b of theprecursor fiber strand 10 at the outside of the heat treatment chamber2, a circulation duct 8 that circulates hot air in the hot air blowingnozzles 4, the heat treatment chamber 2, and the hot air suctioningnozzles 5, and a hot air heater 6 and an air blower 7 that are installedin the circulation duct 8. The sheet-shaped precursor fiber strand 10 issequentially hung and wound around the guide rolls 3 disposed as pluralstages, and is guided into or out of the heat treatment chamber 2through the first and second guide ports 9 a and 9 b of theflame-resistant heat treatment furnace 1.

FIG. 2 illustrates a top cross-sectional view of the flame-resistantheat treatment furnace according to this embodiment. As illustrated inthe same drawing, the hot air that blows from the hot air blowing nozzle4 flows into the heat treatment chamber 2 in parallel to pluralprecursor fiber strands 10 that run while being flat in a sheet shape,is suctioned by the hot air suctioning nozzles 5, passes through thecirculation duct 8 so that the temperature is controlled at apredetermined temperature by the hot air heater 6, and is supplied tothe hot air blowing nozzle 4 again by the air blower 7.

FIG. 3 illustrates an enlarged top view of the hot air blowing nozzle 4that is provided in the flame-resistant heat treatment furnace of theinvention. The hot air blowing nozzle 4 has a rectangular cross-section,and includes a hot air inlet 40, a direction changing plate 41 thatchanges the direction of the hot air by 90°, a porous plate 42 thatreduces a variation in wind speed caused by pressure loss, and arectifying member 43 that trims the hot air in a direction in which theprecursor fiber strand 10 runs in the heat treatment chamber 2 (see FIG.2).

In the invention, the porous plate 42 is a plate provided with pluralopenings.

It is desirable that plural openings having the same shape and size beuniformly arranged in the porous plate 42.

It is desirable that the air blowing speed of the hot air blowing fromeach of the hot air blowing nozzles 4 disposed at the upper and lowerpositions with the precursor fiber strand 10 interposed there between bethe same speed. Further, it is desirable to decrease a variation in flowspeed of the hot air blowing from the hot air blowing nozzles 4 in thewidth direction and the height direction as small as possible, and it isdesirable that a variation in wind speed at the point of 2 m on thedownstream side of the air blowing nozzle fall within the average windspeed ±20%. It is more desirable that a variation in wind speed fallwithin the average wind speed ±10%.

It is desirable that a ratio (A/B) between a hot air passage distance A(see FIG. 3) in which the hot air passes through the rectifying member43 and a maximum distance B of the rectifying member 43 in thehorizontal direction be equal to or larger than four. When the ratio isequal to or larger than 4.0, the hot air may have a desirable linearadvancing property that causes the hot air changing in direction fromthe hot air inlet 40 of the hot air blowing nozzle 4 to blow in parallelto the running direction of the precursor fiber strand 10. Meanwhile,when the rectifying member 43 is formed with a long length, the lengthof the nozzle increases in the yarn direction, and hence a regionincreases which sandwiches the precursor fiber strand 10 in theflame-resistant heat treatment furnace 1 and disturbs the flow of thehot air. That is, heat may not be removed from the precursor fiberstrand 10 that repeats an exothermal reaction according to the design,and hence the risk of a runaway reaction increases. The ratio A/B isdesirably 10 or less, more desirably 7 or less, and most desirably 5 orless.

Further, the rate of hole area of the porous plate 42 is 15 to 35% inorder to reduce a variation in wind speed caused by the pressure loss.It is desirable that the rate of hole area be equal to or larger than15% in that the pressure loss is suppressed at the position of theporous plate, and it is more desirable that the rate of hole area beequal to or larger than 17%. It is desirable that the rate of hole areabe equal to or smaller than 35% in that a variation in wind speed isreduced by the pressure loss in the length direction of the hot airblowing nozzle 4. Further, the rate of hole area of 30% or less is moredesirable, and the rate of hole area of 25% or less is most desirable.

As for the positional relation between one opening of the porous plate42 and one opening of the rectifying member 43, it is desirable that 80%or more of the area of one opening of the porous plate 42 exist withinone opening of the rectifying member 43 when the facing surfaces of theporous plate 42 and the rectifying member 43 overlap each other in thatthe hot air blowing speed from the hot air blowing nozzle 4 becomesuniform.

It is desirable that the opening center of the porous plate 42 exist onthe line connected to the middle point of the rectifying member 43 inthe width direction.

With the positional relation, the hot air may smoothly flow through theporous plate 42 and the rectifying member 43, and hence the gradientstream may be also easily suppressed.

The diameter d equivalent to the opening of the porous plate 42 in theinvention may be appropriately determined from the blockage state of theporous plate 42 and the uniform hot air blowing speed of the hot airblowing nozzle 4. However, from the viewpoint of preventing the blockageof the porous plate 42, the lower limit of the equivalent diameter ofthe porous plate 42 is desirably 5 mm or more, more desirably 8 mm ormore, and most desirably 10 mm or more.

Further, the upper limit of the equivalent diameter of the porous plate42 is desirably 25 mm or less, more desirably 20 mm or less, and mostdesirably 16 mm or less from the viewpoint of the uniform hot airblowing speed from the hot air blowing nozzle 4.

The equivalent diameter d is obtained by the following equation.d=4×S/L

Here, S indicates the opening area (mm²) and L indicates the openingperimeter (mm).

In the invention, it is desirable that the relation between the maximumdistance B (mm) of one opening of the rectifying member 43 in thehorizontal direction and the equivalent diameter d (mm) of the porousplate 42 satisfy the condition of 0≦B−d≦20.

When the value obtained by subtracting the equivalent diameter d (mm) ofthe porous plate 42 from the maximum distance B (mm) of one opening ofthe rectifying member 43 in the horizontal direction is 0 (mm) or more,the hot air may smoothly flow through the rectifying member 43. Further,when the value obtained by subtracting the equivalent diameter d (mm) ofthe porous plate 42 from the maximum distance B (mm) of one opening ofthe rectifying member 43 in the horizontal direction is 20 (mm) or less,the linear advancing property of the hot air blowing to the heattreatment chamber may be easily improved.

It is desirable that the value obtained by subtracting the equivalentdiameter d (mm) of the porous plate 42 from the maximum distance B (mm)of one opening of the rectifying member 43 in the horizontal directionbe 5 (mm) or more in that the hot air smoothly flow through therectifying member 43. Further, it is more desirable that the valueobtained by subtracting the equivalent diameter d (mm) of the porousplate 42 from the maximum distance B (mm) of one opening of therectifying member 43 in the horizontal direction be 15 (mm) or less fromthe viewpoint of the linear advancing property of the hot air.

As the rectifying member 43, a rectifying plate obtained by arrangingflat plates in parallel, a honeycomb member obtained in the market, or amember obtained by the combination of flat plates in a lattice shape areused. In order to obtain the uniform blowing speed between therectifying members 43 inside the heat treatment chamber 2 in the widthdirection, it is desirable that the opening pitch P1 of the opening ofthe porous plate 42 be in the range of 0.995 to 1.005 times of theopening pitch P2 of the opening of the rectifying member. When theopening pitch becomes smaller than 0.995 times, the displacement amountof the relative position between the opening of the porous plate 42 andthe opening of the rectifying member 43 increases, and hence there is aconcern that the wind speed distribution in the width direction insidethe heat treatment chamber 2 may be degraded. Further, even when theopening pitch becomes larger than 1.005 times, the displacementdirections become opposite to each other, and hence there is a concernthat the wind speed distribution may be degraded in the same way. Moredesirably, the opening pitch P2 of the rectifying member and the openingpitch P1 of the porous plate are equal to each other as illustrated inFIG. 5.

The shape of the direction changing plate 41 has an inclination set inthe range in which the ratio (x/L) of the facing distance x between thedirection changing plate 41 and the porous plate 42 of the tip in thenozzle length direction with respect to the length L of the hot airblowing nozzle 4 is smaller than 0.030 times and the ratio (w/L) of theinlet width w of the hot air blowing nozzle 4 with respect to the nozzlelength L of the hot air blowing nozzle 4 is smaller than 0.50 times (seeFIG. 3). By the inclination set in this range, the direction of the hotair may be changed and the flow amount from the hot air inlet 40 to thenozzle tip is controlled. Accordingly, the air blowing speed may becomeuniform throughout the nozzle length L.

FIG. 4 schematically illustrates the positional relation between theporous plate 42 and the rectifying member 43 of the hot air blowingnozzle 4.

It is desirable that the facing distance y (see FIG. 3) between theopening surfaces of the porous plate 42 and the rectifying member 43 bewithin 7 mm. At the position where the hot air immediately passesthrough the porous plate, the direction of the hot air is not parallelto the running direction of the precursor fiber strand 10, and thestream line is inclined. For this reason, it is desirable that thedistance y between the porous plate 42 and the rectifying member 43 bewithin 7 mm in that the influence of the inclination of the stream lineat the tip side of the hot air blowing nozzle 4 in the length directionis suppressed and the air blowing speed distribution of the hot air isuniform.

Further, it is desirable that the distance y between the porous plate 42and the rectifying member 43 having a lattice shape or a honeycomb shapebe close to 0 as much as possible.

In order to keep the relative positional relation between the porousplate 42 and the rectifying member 43, the connection there between isperformed by using a positioning member. Any method may be employed aslong as the positional relation between the rectifying member and theporous plate is uniformly fixed so that the hot air blowing operation isnot influenced. For example, exemplified are a method of fixing theporous plate 42 to the rectifying member 43 without any displacement inthe width direction inside the heat treatment chamber 2 by uprightlysetting a positioning pin having a width equal to the gap of therectifying member adjacent to the porous plate 42 and inserting therectifying member 43, a method of inserting the outer frame of theporous plate to the outer frame of the rectifying member, a method offixing the porous plate to the rectifying member by a bolt and a nut, amethod of inserting protrusions having the same shape as that of theopenings of the rectifying member mounted on the porous plate to theseveral openings of the rectifying member, and a method of installing ahook to a designated place. Further, it is desirable that the connectionmember be detachable for the convenience of maintenance.

FIG. 7 schematically illustrates a method of opening the porous plate ofthe hot air blowing nozzle. The number of the holes of the porous plate42 does not need to be essentially equal to the number of holes of therectifying member 43 having a lattice shape or a honeycomb shape, andthe hole forming positions of the porous plate 42 may be arbitrarily setin order to cause the rate of hole area to fall within a predeterminedrange. At this time, it is desirable to form the hole forming positionsof the porous plate 42 so as to be balanced as a whole.

As described above, according to the flame-resistant heat treatmentfurnace using the hot air blowing nozzle of the invention, the structureof the hot air blowing nozzle may be simplified, and the heat transferperformance throughout the inside of the heat treatment chamber maybecome uniform by obtaining the uniform distribution of the air blowingspeed of the hot air. Further, the blockage of the nozzle caused by asilicone compound may be easily prevented by using a member having alarge opening.

Further, when the flame-resistant heat treatment furnace has theconfiguration of FIG. 2 such that the circulation duct 8 is disposed soas to be symmetrical in the width direction of the precursor fiberbundle (the precursor fiber strand) 10 while being located at theoutside, the width of the treatment subject passage path is set to belarge, and the hot air blowing nozzles 4 are disposed while beingsymmetrical in the length direction so as to arrange the backs thereofin a line, the treatment amount per unit time may be increased whilekeeping the uniform flow speed distribution.

EXAMPLES

Hereinafter, examples of the invention will be described in detail.However, the invention is not limited to these examples.

The measurement method is as below.

(Wind Speed)

The wind speed inside the flame-resistant heat treatment furnace wasmeasured by a vane wind speed meter (trade name: “SK-95 F” manufacturedby SATO CO., LTD.).

Example 1

In the hot air blowing nozzle illustrated in FIG. 3, the nozzle length Lwas set as 2050 mm, the width w of the hot air inlet was set as 700 mm,the distance x between the tip of the direction changing plate and theporous plate was set as 50 mm, and the equivalent diameter d of theporous plate was set as 12 mm. At this time, the ratio w/L of the widthw of the hot air inlet with respect to the length L of the hot airblowing nozzle was set as 0.34, and the ratio x/L of the distance xbetween the tip of the direction changing plate and the porous platewith respect to the length L of the hot air blowing nozzle was set as0.024.

Further, a stainless honeycomb (having a trade name “SH-01100-26”, anopposite side dimension of 26 mm, a plate thickness of 0.1 mm, and adepth of 145 mm) manufactured by San Technology, Inc. was used as therectifying member. That is, the ratio A/B was 4.8%. At this time, theopening pitch P1 of the holes of the porous plate illustrated in FIG. 4was set as the pitch of 22.5 mm equal to the opening pitch P2 of thestainless honeycomb. At this time, the rate of hole area was 17%.Further, as illustrated in FIG. 5, the center positions of the openingsof the porous plate and the rectifying member were adjusted so as tomatch one another when the porous plate and the rectifying memberoverlapped each other. Further, the porous plate and the rectifyingmember were closely attached to each other so that the gap y became 0mm.

Hot air was caused to blow to the nozzle by adjusting the air blowingamount by a fan (not illustrated) so as to keep the average wind speedof 3 m/s at a position away from the air blowing nozzle by 2 m, and thewind speed measurement was performed at the position of 2 m on thedownstream side of the air blowing nozzle inside the hot air treatmentchamber. Further, total seven measurement positions of 265 mm, 365 mm,705 mm, 1145 mm, 1585 mm, 1925 mm, and 2025 mm were set at thedownstream position of 2 m in the length direction of the air blowingnozzle based on the hot air inlet. The wind speed measurement wasperformed ten times at each of the measurement positions, and theaverage was set as the wind speed value at each of the positions.Further, the average wind speed and the wind speed distribution werecalculated in the respective conditions at seven points in the nozzlelength direction using the wind speed value.

As a result, as listed in Table 1, the result was satisfactory such thata variation in wind speed in the nozzle length direction was ±5%.

Example 2

The wind speed was measured as in Example 1 except that the displacementamount of the openings of the respective centers of the porous plate andthe honeycomb (the rectifying member) was 1.5 mm when the openingsoverlapped each other on the same plane. As listed in Table 1, theresult was satisfactory such that a variation in wind speed in thenozzle length direction was ±5%.

Example 3

In the hot air blowing nozzle illustrated in FIG. 3, the nozzle length Lwas set as 1850 mm, the width w of the hot air inlet was set as 375 mm,the distance x between the tip of the direction changing plate and theporous plate was set as 10 mm, and the equivalent diameter d of theporous plate was set as 14 mm. At this time, the ratio w/L of the widthw of the hot air inlet with respect to the length L of the hot airblowing nozzle was set as 0.20, and the ratio x/L of the distance xbetween the tip of the direction changing plate and the porous platewith respect to the length L of the hot air blowing nozzle was set as0.005.

Further, a stainless honeycomb (having a trade name “SH-01100-16”, anopposite side dimension of 16 mm, a plate thickness of 0.1 mm, and adepth of 80 mm) manufactured by San Technology, Inc. was used as therectifying member. That is, the ratio A/B was 4.3%. At this time, theopening pitch P1 of the holes of the porous plate illustrated in FIG. 4was set as the pitch of 13.9 mm equal to the opening pitch P2 of thestainless honeycomb. At this time, the rate of hole area of the porousplate was 29%. Further, the center positions of the openings of theporous plate and the rectifying member were adjusted so as to match oneanother when the porous plate and the rectifying member overlapped eachother. Furthermore, the porous plate and the rectifying member wereclosely attached to each other so that the gap y became 0 mm.

Hot air was caused to blow to the nozzle by adjusting the air blowingamount by a fan (not illustrated) so as to keep the average wind speedof 3 m/s at a position away from the air blowing nozzle by 2 m, and thewind speed measurement was performed at the position of 2 m on thedownstream side of the air blowing nozzle. Further, total seven windspeed measurement positions of 100 mm, 247 mm, 594 mm, 941 mm, 1288 mm,1635 mm, and 1750 mm were set at the downstream position of 2 m in thelength direction of the air blowing nozzle based on the hot air inlet.The wind speed measurement was performed ten times at each of themeasurement positions, and the average was set as the wind speed valueat each of the positions. Further, the average wind speed and the windspeed distribution were calculated in the respective conditions at sevenpoints in the nozzle length direction using the wind speed value.

As listed in Table 1, the result was satisfactory such that a variationin wind speed in the nozzle length direction was ±9%.

Example 4

The wind speed was measured as in Example 3 except that the horizontaldisplacement amount z of the respective centers when the openings of theporous plate and the rectifying member overlapped each other on the sameplane was set as 1 mm. As listed in Table 1, the result was satisfactorysuch that a variation in wind speed in the nozzle length direction was±9%.

The conditions in Examples 1 to 4 all satisfied the numerical ranges ofclaim, and a variation in wind speed distribution was satisfactory.Thus, air was caused to uniformly flow into the respective honeycombholes by appropriately setting the pressure loss of the porous plate,the inclination of the direction changing plate, and the arrangementrelation between the porous plate and the honeycomb, and the wind speeddistribution became uniform by the linear advancing property in adirection parallel to running direction of the precursor fiber by thepassage of the air through a predetermined length of the honeycomb.Further, compared to Examples 1 and 3, in Examples 2 and 4, therespective centers of the openings of the porous plate and therectifying member when the porous plate and the rectifying memberoverlapped each other on the same plane within the range satisfyingclaim 2 were displaced from each other, but there was no influence on avariation in wind speed.

Example 5

The wind speed was measured as in Example 1 except that the width w ofthe hot air inlet was set as 1200 mm, that is, the ratio (w/L) was setas 0.59. As listed in Table 1, the result was satisfactory such that avariation in wind speed in the nozzle length direction became ±10%.

Example 6

The wind speed was measured as in Example 5 except that the distance xbetween the tip of the direction changing plate and the porous plate wasset as 80 mm, that is, the ratio x/L was set as 0.039%. As listed inTable 1, the result was satisfactory such that a variation in wind speedin the nozzle length direction became ±9%.

Example 5 is out of the range of the condition (9) in that the inletwidth of the hot air blowing nozzle is increased, and Example 6 is outof the ranges of the conditions (8) and (9) in that the distance betweenthe porous plate and the direction changing plate at the tip of thenozzle is increased. In all examples, the wind speed distribution wassatisfactory, but there was a tendency that a variation in wind speedincreased compared to Example 1 satisfying all claims.

Example 7

The wind speed measurement was performed as in Example 1 except that thehorizontal displacement distance between the center of the circumscribedcircle and the center of the porous plate was set as 4 mm when theopenings of the porous plate and the rectifying member overlapped eachother on the same plane in a state where the opening pitch P1 of theholes of the porous plate was set as the pitch of 22.5 mm equal to theopening pitch P2 of the stainless honeycomb. As listed in Table 1, theresult was satisfactory such that a variation in wind speed in thenozzle length direction became ±16%.

In Example 7, since a drift is generated inside the honeycomb when thehole center of the porous plate and the center of the circumscribedcircle are displaced from each other in the horizontal direction whilethe openings of the porous plate and the rectifying member overlap eachother on the same plane, there is a tendency that the value of avariation in wind speed increases compared to Example 1.

Example 8

The wind speed was measured as in Example 1 except that the gap ybetween the facing opening surfaces between the porous plate and thehoneycomb as the rectifying member was set as 5 mm. As listed in Table1, the result was satisfactory such that a variation in wind speed inthe nozzle length direction became ±15%.

Example 9

The wind speed was measured as in Example 1 except that the gap ybetween the facing opening surfaces between the porous plate and thehoneycomb as the rectifying member was set as 10 mm. As listed in Table1, the result was satisfactory such that a variation in wind speed inthe nozzle length direction became ±20%.

Example 8 is within the range of the condition (7) and Example 9 is outof the range of the condition (7) since the distance between the porousplate and the honeycomb is increased. The stream line that flows fromthe hot air inlet and passes through the porous plate is inclined towardthe nozzle tip in the running direction of the precursor fiber.Accordingly, when the distance between the porous plate and thehoneycomb is large, the air dose not uniformly flow into the respectivehoneycomb hole, and the wind speed at the nozzle tip becomes fast, sothat a variation in wind speed increases.

Comparative Example 1

The wind speed measurement was performed as in Example 1 except that thehole diameter d of the porous plate was set as 18 mm and the rate ofhole area was set as 37%. As listed in Table 1, a variation in windspeed was large such that a variation in wind speed in the nozzle lengthdirection was ±45%.

Comparative Example 1 is out of the range of the condition (2) since therate of hole area is large. When the rate of hole area increases toomuch, the wind speed of the air blowing from the hot air blowing nozzletip increases, and hence the wind speed distribution is largelydegraded.

Comparative Example 2

A stainless honeycomb (having a trade name “SH-01100-26”, an oppositeside dimension of 26 mm, a plate thickness of 0.1 mm, and a depth of 100mm) manufactured by San Technology, Inc. was used as the rectifyingmember. That is, the ratio A/B was 3.3%. The wind speed measurement wasperformed as in Example 1 in the other conditions. As listed in Table 1,a variation in wind speed was large such that a variation in wind speedin the nozzle length direction was ±25%.

Comparative Example 3

A stainless honeycomb (having a trade name “SH-01100-16”, an oppositeside dimension of 16 mm, a plate thickness of 0.1 mm, and a depth of 50mm) manufactured by San Technology, Inc. was used as the rectifyingmember. That is, the ratio A/B was 2.7%. The wind speed measurement wasperformed as in Example 3 in the other conditions. As listed in Table 1,a variation in wind speed was large such that a variation in wind speedin the nozzle length direction was ±35%.

Comparative Examples 2 and 3 are within the range of the condition (1)since the hot air passage distance of the honeycomb is short. When thehot air passage distance of the honeycomb is too short, the hot airblows as the gradient stream at the blowing port of the hot air blowingnozzle, and hence a variation in wind speed increases as illustrated inComparative Examples 2 and 3. Thus, it is desirable that the ratio A/Bof the hot air passage distance of the rectifying member with respect tothe distance between the opposite sides of the honeycomb member or thelattices of the rectifying member be 4.0 times or more.

TABLE 1 EQUIVALENT EXAMPLE 1 EXAMPLE 2 EXAMPLE 3 EXAMPLE 4 EXAMPLE 5EXAMPLE 6 EXAMPLE 7 CORRESPONDING 12 12 14 14 12 12 12 DIAMETER d (mm)OF POROUS PLATE OPENING RATIO ·(—) OF 0.17 0.17 0.29 0.29 0.17 0.17 0.17POROUS PLATE RATE OF HOLE AREA HOT AIR PASSAGE 145 145 80 80 145 145 145DISTANCE A (mm) OF RECTIFYING MEMBER HORIZONTAL MAXIMUM 30 30 18.5 18.530 30 30 DISTANCED (mm) OF RECTIFYING MEMBER A/B 4.8 4.8 4.3 4.3 4.8 4.84.8 OPENING PITCH P1 (mm) OF 22.5 22.5 13.9 13.9 22.5 22.5 22.5 POROUSPLATE OPENING PITCH P2 (mm) OF 22.5 22.5 13.9 13.9 22.5 22.5 22.5RECTIFYING MEMBER P1/P2 1.0 1.0 1.0 1.0 1.0 1.0 1.0 HORIZONTAL 0.0 1.50.0 1.0 0.0 0.0 4.0 DISPLACEMENT AMOUNT z (mm) OF POROUS PLATE ANDRECTIFYING MEMBER GAP y (mm) OF POROUS 0 0 0 0 0 0 0 PLATE ANDRECTIFYING MEMBER NOZZLE LENGTH L (mm) 2050 2050 1850 1850 2050 20502050 DISTANCE × (mm) 50 50 10 10 50 80 50 BETWEEN TIP OF BACK SURFACEPLATE AND POROUS PLATE x/L 0.024 0.024 0.005 0.005 0.024 0.039 0.024INLET WIDTH w (mm) 700 700 375 375 1200 1200 700 w/L 0.34 0.34 0.20 0.200.59 0.59 0.34 WIND SPEED DISTRIBUTION 5 5 9 9 10 9 16 (·%) AT 2 m ONDOWNSTREAM SIDE OF BLOWING NOZZLE COMPARATIVE COMPARATIVE COMPARATIVEEQUIVALENT EXAMPLE 8 EXAMPLE 9 EXAMPLE 1 EXAMPLE 2 EXAMPLE 3CORRESPONDING 12 12 18 12 14 DIAMETER d (mm) OF POROUS PLATE OPENINGRATIO ·(—) OF 0.17 0.17 0.37 0.17 0.29 POROUS PLATE RATE OF HOLE AREAHOT AIR PASSAGE 145 145 145 100 50 DISTANCE A (mm) OF RECTIFYING MEMBERHORIZONTAL MAXIMUM 30 30 30 30 18.5 DISTANCED (mm) OF RECTIFYING MEMBERA/B 4.8 4.8 4.8 3.3 2.7 OPENING PITCH P1 (mm) OF 22.5 22.5 22.5 22.513.9 POROUS PLATE OPENING PITCH P2 (mm) OF 22.5 22.5 22.5 22.5 13.9RECTIFYING MEMBER P1/P2 1.0 1.0 1.0 1.0 1.0 HORIZONTAL 0.0 0.0 0.0 0.00.0 DISPLACEMENT AMOUNT z (mm) OF POROUS PLATE AND RECTIFYING MEMBER GAPy (mm) OF POROUS 5 10 0 0 0 PLATE AND RECTIFYING MEMBER NOZZLE LENGTH L(mm) 2050 2050 2050 2050 1850 DISTANCE × (mm) 50 50 50 50 10 BETWEEN TIPOF BACK SURFACE PLATE AND POROUS PLATE x/L 0.024 0.024 0.024 0.024 0.005INLET WIDTH w (mm) 700 700 700 700 375 w/L 0.34 0.34 0.34 0.34 0.20 WINDSPEED DISTRIBUTION 15 20 45 25 35 (·%) AT 2 m ON DOWNSTREAM SIDE OFBLOWING NOZZLE

EXPLANATIONS OF LETTERS OR NUMERALS

-   -   1: flame-resistant heat treatment furnace    -   2: heat treatment chamber    -   3: guide roll    -   4: hot air blowing nozzle    -   5: hot air suctioning nozzle    -   6: hot air heater    -   7: air blower    -   8: circulation duct    -   9 a: first guide port    -   9 b: second guide port    -   10: precursor fiber strand    -   40: hot air inlet    -   41: direction changing plate    -   42: porous plate    -   43: rectifying member

The invention claimed is:
 1. A flame-resistant heat treatment furnacecomprising: a heat treatment chamber that causes hot air to flow in adirection parallel to a running direction of a precursor fiber strandand heats the precursor fiber strand; a hot air blowing nozzle thatchanges a flowing direction of the hot air and thereafter introduces thehot air into the heat treatment chamber; and a hot air suctioning nozzlethat is installed at a position away from the hot air blowing nozzle andsuctions the hot air, wherein the hot air blowing nozzle comprises aporous plate and a rectifying member that satisfy conditions (1) to (4):(1) A/B≧4.0; (2) 0.15≦α≦0.35; (3) 0≦B−d≦20; and (4) 80% or more of anarea of one opening of the porous plate when causing facing surfaces ofthe porous plate and the rectifying member to overlap is included in oneopening of the rectifying member, where A is a hot air passage distance(mm) of the rectifying member, B is a horizontal maximum distance (mm)of one opening of the rectifying member, α is a rate of hole area of theporous plate, and d is an equivalent diameter (mm) of the porous plate,and the hot air is sent to the heat treatment chamber through the porousplate and the rectifying member.
 2. The flame-resistant heat treatmentfurnace according to claim 1, wherein the equivalent diameter d (mm) ofthe porous plate satisfies a condition (5) of 10≦d≦20.
 3. Theflame-resistant heat treatment furnace according to claim 2, wherein anopening pitch P1 (mm) of openings of the porous plate and an openingpitch P2 (mm) of openings of the rectifying member satisfy a condition(6) of 0.995×P2≦P1≦1.005×P2.
 4. The flame-resistant heat treatmentfurnace according to claim 2, wherein a distance y (mm) between facingopening surfaces of the porous plate and the rectifying member satisfiesa condition (7) of 0≦y≦7.
 5. The flame-resistant heat treatment furnaceaccording to claim 2, wherein a cross-sectional shape of the rectifyingmember in a hot air passage direction is a lattice shape or a honeycombshape.
 6. The flame-resistant heat treatment furnace according to claim2, wherein the porous plate and the rectifying member are connected toeach other by a positioning member.
 7. The flame-resistant heattreatment furnace according to claim 2, wherein the porous plate and therectifying member are detachable from each other.
 8. The flame-resistantheat treatment furnace according to claim 2, wherein the hot air blowingnozzle further comprises a direction changing plate that changes a hotair flow direction, and satisfies a condition (8) of (x/L)<0.030 and acondition (9) of (w/L)<0.50, where x is a distance (mm) between theporous plate at a nozzle tip and the direction changing plate at thenozzle tip, L is an entire length (mm) of the hot air blowing nozzle ina depth direction, and w is an inlet width (mm) of the hot air blowingnozzle.
 9. The flame-resistant heat treatment furnace according to claim2, wherein an installation position of the porous plate is adjustable.10. The flame-resistant heat treatment furnace according to claim 1,wherein an opening pitch P1 (mm) of openings of the porous plate and anopening pitch P2 (mm) of openings of the rectifying member satisfy acondition (6) of 0.995×P2≦P1≦1.005×P2.
 11. The flame-resistant heattreatment furnace according to claim 1, wherein a distance y (mm)between facing opening surfaces of the porous plate and the rectifyingmember satisfies a condition (7) of 0≦y≦7.
 12. The flame-resistant heattreatment furnace according to claim 1, wherein a cross-sectional shapeof the rectifying member in a hot air passage direction is a latticeshape or a honeycomb shape.
 13. The flame-resistant heat treatmentfurnace according to claim 1, wherein the porous plate and therectifying member are connected to each other by a positioning member.14. The flame-resistant heat treatment furnace according to claim 1,wherein the porous plate and the rectifying member are detachable fromeach other.
 15. The flame-resistant heat treatment furnace according toclaim 1, wherein the hot air blowing nozzle comprises a directionchanging plate that changes a hot air flow direction, and satisfies acondition (8) of (x/L)<0.030 and a condition (9) of (w/L)<0.50, where xis a distance (mm) between the porous plate at a nozzle tip and thedirection changing plate at the nozzle tip, L is an entire length (mm)of the hot air blowing nozzle in a depth direction, and w is an inletwidth (mm) of the hot air blowing nozzle.
 16. The flame-resistant heattreatment furnace according to claim 1, wherein an installation positionof the porous plate is adjustable.
 17. A method of manufacturing acarbon fiber comprising: heating the carbon fiber precursor strand inthe flame-resistant heat treatment furnace according to claim 1.